3.4 swap, found engine block, but what else do I need

[smartrepair]

Hi everybody

I´ve been trying to find an 3.4 engine. Now I found pretty cheap one, but it´s not complete, there´s no air intake/throttlebody assembly.

I suppose I cannot use even a part of my 1998 Boxter 2.5 assembly? I was looking at the other posts and the 3.4 looks different... as I´ve undestood the exhaust side will fit, although not ideal.

What about the cooling system of the engine: as it´s bigger souns logical that additional cooling is required. How have you solved that?

What experience do you have with the swap in general? Any problems? And the positive experiences???

Thanks

Kare, Spaijn

[Peter986]

I think the throttle body is a different size for the 3.4.

The stock exhaust (at least on my '98) will fit the new engine. However, it works much better, especially at the top end, with headers and sport cats. The stock muffler is adequate.

The only cooling problem I had before I put on a center radiator was when I was on the track at NHIS on a 90+ degree F day. For street driving you should have no problem.

I have 45000 miles since the swap was done on my car. The only problem I had was a problem with the replacement computer after a year or so. I think it was just defective-it is fine now. The work was done by Autosport Engineering in Stow, Mass.

[Stefan]

How much did AutoSport charge and what was included in that price? Just curious because I am debating doing it myself versus having someone do it for me (I'm in Boston).

[Peter986]

The parts costs were about $3,000. The big items were:

$550 - engine mounting kit

$1200 - Sachs sport clutch, pressure plate, throw out bearing

$700 - dual mass flywheel (the original one needed replacement)

$350 - throttle housing to convert from e-gas to cable

This also included new anti-freeze, new Mobil 1 oil, oil filter, etc., but does not include headers and sport cats. The car ran great with the original headers and cats, but ran out of wind at about 5500 rpm. I subsequently had a cone air filter, performance headers and cats installed and it now pulls strongly all the way to red line. This also does not include the cost of the motor and ECU.

Labor ran $2000. This also included reprogramming the ECU. Remember this was 4 years ago and mine was the first conversion they did so they were learning to some extent. They have done some since then so I would guess that it would cost less now. Maybe the parts costs are lower now as well. I am sure they can give you a good estimate.

The car is transformed. It makes it into what it should have been to start with.

Email me if you want more detail.

[BoxsterRS]

The parts costs were about $3,000. The big items were:

$550 - engine mounting kit

$1200 - Sachs sport clutch, pressure plate, throw out bearing

$700 - dual mass flywheel (the original one needed replacement)

$350 - throttle housing to convert from e-gas to cable

This also included new anti-freeze, new Mobil 1 oil, oil filter, etc., but does not include headers and sport cats. The car ran great with the original headers and cats, but ran out of wind at about 5500 rpm. I subsequently had a cone air filter, performance headers and cats installed and it now pulls strongly all the way to red line. This also does not include the cost of the motor and ECU.

Labor ran $2000. This also included reprogramming the ECU. Remember this was 4 years ago and mine was the first conversion they did so they were learning to some extent. They have done some since then so I would guess that it would cost less now. Maybe the parts costs are lower now as well. I am sure they can give you a good estimate.

The car is transformed. It makes it into what it should have been to start with.

Email me if you want more detail.

How much did the engine cost you ?

[ralegen]

How many horses does the 3.4 have again?

[Peter986]

How much did the engine cost you ?

These days I think you can get a used one for $4-$5K. When I got mine, I bought one new from Porsche. It was a lot more. :(

How many horses does the 3.4 have again?

I think it has 295 hp stock in a 996. Supposedly, in this configuration it has 310 hp. I have no way of knowing if it is that high or not.

[smartrepair]

I bought the engine block. Now found cheap Boxter S (3.2) intake. Does it fit????

The engine block is without any intake, throttlebody etc.

Plese advise quickly, I have to make desicions..........

kare

[Darth Coupe]

Peter, we are experiencing the same that you did on our 3.4 swap with the stock exhaust system. I am currently on the search for upgrades for the headers and cats and may do an exhaust, not sure. Where did you go to get yours? Are they custom or are they performance 3.2 parts?

Thanks,

TJ

[Peter986]

Peter, we are experiencing the same that you did on our 3.4 swap with the stock exhaust system. I am currently on the search for upgrades for the headers and cats and may do an exhaust, not sure. Where did you go to get yours? Are they custom or are they performance 3.2 parts?

This stuff was made by TTP in Germany. It is all very nice stuff. We did have a problem with the intake system. The air box was very nice, but they were using a flexible hose to connect the air box to the throttle body. The hose rubbed against something and caused an air leak and I would think a smooth pipe would be better for intake. The guys at AutoSport fabricated a better set up for me. Perhaps by now TTP has a better solution.

[Darth Coupe]

Peter, we are experiencing the same that you did on our 3.4 swap with the stock exhaust system. I am currently on the search for upgrades for the headers and cats and may do an exhaust, not sure. Where did you go to get yours? Are they custom or are they performance 3.2 parts?

This stuff was made by TTP in Germany. It is all very nice stuff. We did have a problem with the intake system. The air box was very nice, but they were using a flexible hose to connect the air box to the throttle body. The hose rubbed against something and caused an air leak and I would think a smooth pipe would be better for intake. The guys at AutoSport fabricated a better set up for me. Perhaps by now TTP has a better solution.

Thanks Peter. I had a similar problem with our intake. At the first track event we went to my first attempt of extending the tube with some flexible material/tape did not work, got a hole and messed up the engine. The second track event which was one week later had the fix from the previous one which was dryer hose. It worked for a good while, but rubbed a hole on the last session of the last day. My wife had to trailer her car home on my trailer. I have got a steel tube now with some intercooler couplers to connect to the plastic ends. This should be good enough to not rub anymore holes.

[Peter986]

I have got a steel tube now with some intercooler couplers to connect to the plastic ends. This should be good enough to not rub anymore holes.

Can you give me some details on where you got the tube and intercooler couplers?

[Darth Coupe]

I have got a steel tube now with some intercooler couplers to connect to the plastic ends. This should be good enough to not rub anymore holes.

Can you give me some details on where you got the tube and intercooler couplers?

Well, the tube came off of just an exhaust tube availible anywhere like autozone. If I were to do it again I would probably get an aluminum one, but that can be done later. I just cut it down to about 10" if I remember correctly. It depends on how much of the original plastic intake ends you use. The intercooler couplers I got off of Ebay. I needed to have something that will strech as the OD of the plastic intake ends is 3.1" and they only sell 3.0" ID couplers. So I got some with no fabric reinforcements.

[smartrepair]

How much have you paid for the DME reprograming?

Can you recommend any companies?

Kare